Welders Visual Inspection Handbook 2013 WEB New PDF

WELDERS
Visual Inspection
HANDBOOK
May 2013
-- NOTE -This handbook is NOT intended to serve as a work

procedure or to replace any existing procedures. It is
solely intended to provide basic information about
weld conditions, weld gauges, symbols and weld
terms. Refer to local procedures for technical or
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Click on any of the items under the Table of Contents to go to that
Table of Contents
Visual Inspection Responsibilities and Technique
How to Measure Fillet Weld Size
VT Attributes Cracks

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Burn Through
Incomplete Fusion
Roughness
Overlap

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Incomplete Penetration
Undercut
Corner-Melt
End-Melt

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Convex Fillet Weld
Arc Strikes
Other Fabrication Scars
Porosity

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Slag
Weld Reinforcement

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2[LGDWLRQ

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Types of Weld Joints
Parts of a Weld
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Standard Welding Symbol Layout
Standard Welding Symbols
Using Finger Gauge
Using Bridgecam Gauge
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Page
i
1
2

6
8
10
12

16
18
20
22

26
28
30
32

36
38

50
53

60
61
67
70

Visual Inspection Responsibilities

1.
2.
When Final visual inspections must be performed:

D
:KHQWKHZHOGLVFRPSOHWHDQGLQWKHQDOVXUface and heat treated conditions
b)
Before other NDT (when required)
c)
Before being made inaccessible for inspection
Where the weld inspection zone:
a)
All work - Completed weld faces plus inch on
both sides of weld shall be visually inspected for
the entire length of the weld.
b)
To gauge weld size:
(1). Gauge where the weld size visually appears to be the smallest
,IWKHZHOGOHQJWKLVYHIHHWRUOHVVJDXJH
a minimum of once per weld
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Visual Inspection Technique

1.
2.
What,QRUGHUWRSHUIRUPQDOYLVXDOLQVSHFWLRQ\RX
need:
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E
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recommended)
c)
Prescription glasses (as required)
How Distance and angle:
a)
The inspectors eyes should be within 24 inches
of the surface to be inspected and
b)
At an angle of at least 30 degrees to the surface
being inspected.
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Table of Contents
How to Measure FILLET WELD SIZE
Leg
Size
(Correct Size)
The leg lengths and throat of the largest triangle that can
EHGUDZQZLWKLQWKHOOHWZHOGFURVVVHFWLRQ
Throat*
Size
Leg
Leg/
Size
Throat*
Leg/
Size
* See parts of a weld
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Table of Contents
CRACKS
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Table of Contents
CRACKS
Denition
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appearing as a broken, jagged or straight line.
NOTE: Cracks are the most serious defect!
Preventive Action
1. Remove contaminants from the joint (rust,
grease, moisture, etc.) prior to welding.
2. Apply and maintain required preheat.
3. Do not allow the base material to cool too
quickly.
0DLQWDLQOOHUPHWDOFRQWUROUHTXLUHPHQWV
8VHFRUUHFWOOHUPHWDOW\SHIRUWKHMRLQW
6. Apply proper bead size and sequencing to
eliminate excessive distortion and/or stress in
the base material.
Corrective Action
Repair in accordance with local procedures.
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UNDERFILL
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UNDERFILL
Denition
The amount of weld that is below a straight line
drawn from the edges of the joint preparation of
a groove weld, with the exception of allowable
undercut.
Preventive Action
1. During welding of the reinforcement, gauge
bead heights in any location that appears to be
lower than the rest of the bead.
2. Adjust amps/volts.
3. Slow travel speed to allow increased weld
puddle volume.
4. Sequence weld passes so that the toes of the
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minimizing valleys.
Corrective Action
Apply additional weld beads until the joint is
DGHTXDWO\OOHGXVKRUDERYH
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BURN THROUGH
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BURN THROUGH
Denition
Excessive heat and/or penetration that results in a
hole completely through the backing ring or strip,
fused root, or adjacent base material.
Preventive Action
1.
2.
3.
4.
Reduce amps/volts.
Increase travel speed.
Maintain appropriate arc length/wire stickout.
Use ceramic tape or approved metal backing
strap on areas with root gap.
Corrective Action
1. Place ceramic tape or approved metal backing
strap on the bottom side of the hole.
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easiest side to weld.
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on the easiest top side, grind or carbon arc the
other side of the hole to sound metal.
4. Weld the other side of the hole to the
appropriate size or height.
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INCOMPLETE FUSION
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INCOMPLETE FUSION
Denition
A situation where the weld metal does not fuse
or completely bond with the base metal or previously deposited weld metal.
Preventive Action
1.
2.
3.
4.
5.
Increase amps/volts.
Decrease travel speed.
Adjust torch/rod angle.
Ensure previous beads are free of overlap
(bead roll-over) and slag prior to welding
additional passes.
Corrective Action
1. Grind or carbon arc the weld to sound metal.
2. Weld repair the affected area.
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ROUGHNESS
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ROUGHNESS
Denition
Sharp ridges (irregularities) or deep valleys between weld beads. The angle formed between the
adjacent beads of the weld must be 90 or greater.
Preventive Action
2. Maintain a consistent travel speed.
3. Maintain appropriate arc length/wire stickout.
4. Adjust torch/rod angle.
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minimizing valleys.
6. Consult local Welding Engineering in cases
where the base material is magnetized.
Corrective Action
2. Weld repair the affected area, if needed.
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OVERLAP
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OVERLAP
Denition
A condition where the weld metal rolls over
forming an angle less than 90. Sometimes
referred to as weld bead rollover.
Preventive Action
1.
2.
3.
4.
Adjust amps/volts.
Corrective Action
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Th
ro
at
UNDERSIZED FILLET WELD
* See parts of a weld
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UNDERSIZED FILLET WELD

Denition
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PHHWWKHPLQLPXPVL]HUHTXLUHPHQWVVSHFLHG
on applicable fabrication documents.
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having undersized weld on sides
that have greater than 90MRLQWWXS
Preventive Action
1. Apply weld layers until weld size is met on all
sides of joint.
3. Decrease travel speed.
4. Maintain proper wire stickout.
6. Avoid over grinding.
7. Sequence weld passes so that the toes of
WKHEHDGVVXIFLHQWO\RYHUODSRQHDQRWKHU
Corrective Action
Apply additional weld passes until the affected
areas are the proper size.
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INCOMPLETE PENETRATION
Pipe
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INCOMPLETE PENETRATION
Denition
A situation where the weld metal does not
penetrate as deeply as required.
Preventive Action
1. Increase the bevel angle and/or root opening
RIWKHWXS'RQRWH[FHHGWKHUHTXLUHPHQWV
of the joint design.
2. Ensure bevel edges of both members are
lined up properly.
3. Increase amps/volts.
Corrective Action
Note: Backgouge 2nd side to full penetration
(remove fusion lines). Often, more than
one fusion line will be present during back
gouging.
2. Weld repair the affected area.
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UNDERCUT
BRIDGECAM
UNDERCUT GAUGE
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UNDERCUT
Denition
A groove melted into the base metal and left
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Preventive Action
1. Decrease amps/volts.
5. Feed more wire into the puddle when manual TIG welding.
6. Increase stop time (dwell time) on weaved
beads.
7. Use undercut gauge to verify acceptability.
Corrective Action
1. Grind the toe of the weld until the unacceptable undercut blends smoothly into the base
material.
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CORNER-MELT
as is
condition
ground
condition
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CORNER-MELT
Denition
A groove melted in a corner of a welded memEHUWKDWLVOHIWXQOOHG
Preventive Action
1. Start welds at end of joint and work inward.
beads.
8. Use undercut or bridgecam gauge to verify
acceptability.
Corrective Action
1. Grind the toe of the weld until the unacceptable corner-melt blends smoothly into the
base material.
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END-MELT
as is condition
ground condition
Gauged
1/4 or less
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END-MELT
Denition
A groove melted into the end of a inch or
OHVVZHOGHGPHPEHUWKDWLVOHIWXQOOHGE\ZHOG
metal.
Preventive Action
1. Start the weld passes at the ends, where
possible.
beads.
8. Use undercut or bridgecam gauge to verify
acceptability.
Corrective Action
1. Grind the toe of the weld until the unacceptable end-melt blends smoothly into the base
material.
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CONCAVE FILLET WELD
gauged
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CONCAVE FILLET WELD

Denition
$OOHWZHOGWKDWVLQNVLQWKHFHQWHU
Preventive Action
1.
2.
3.
4.
5.
Adjust amps/volts.
Decrease travel speed.
Feed more wire into the puddle when manual TIG welding.
beads.
7. Sequence weld passes so that the toes of
WKHEHDGVVXIFLHQWO\FRYHURQHDQRWKHU
Corrective Action
Apply additional weld passes until the concavity
requirements have been met.
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CONVEX FILLET WELD
gauged
Convexity
Check Convexity using

the Proper Size Wire
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Table of Contents
CONVEX FILLET WELD

Denition
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Preventive Action
1.
2.
3.
4.
5.
Adjust amps/volts.
Maintain proper wire stickout.
Feed less wire into the puddle when manual
TIG welding.
6. On multiple pass welds, avoid placing beads
too close together.
Corrective Action
Grind, carbon arc or weld the affected area until
the convexity requirements have been met.
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Table of Contents
ARC STRIKES
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ARC STRIKES
Denition
A discontinuity consisting of any localized remelted metal, heat effected metal, or change in
VXUIDFHSUROHRIDQLVKHGZHOGRUEDVHPDWHrial surface resulting from an electrical arc.
Note: Arc strikes may develop stress risers,
which could lead to cracking.
Preventive Action
1. Prior to energizing welding equipment, replace damaged welding lines and ground
cables.
2. Ensure grounds are properly installed.
3. Hang lines on trees or J-hooks.
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core processes.
5. Do not allow sub-arc tips to contact the base
material.
6. Be careful when striking an arc.
Corrective Action
1. Grind the affected area until the unacceptable arc strike blends smoothly into the base
material or weld face.
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OTHER FABRICATION SCARS
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OTHER FABRICATION SCARS

Denition
Any accidental groove or cut that penetrates
the surface of the metal. Sometimes called
nicks, gouges or handling marks.
Preventive Action
1. Avoid dropping heavy or sharp objects on
welds and surrounding base material.
2. Be careful when grinding, carbon arcing or
using scaling hammer.
3. Use undercut gauge to verify scar acceptability.
Corrective Action
1. Grind the affected area until the unacceptable fabrication scar blends smoothly into
the base material or weld face.
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POROSITY
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POROSITY
Denition
Open holes formed by gas that was trapped
when the weld cooled. Sometimes called pinholes.
Preventive Action
5. Use the largest size gas cup possible and
keep it free of spatter.
6. Position wind screens between the welding
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Corrective Action
1. Completely remove porosity from all intermediate weld areas.
2. Grind or carbon arc the affected area until the
unacceptable porosity is removed from the
weld.
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SPATTER
A 1/8" wide x 1/8" deep notch

is for verifying size of spatter
1/4"
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SPATTER
Denition
The metal particles expelled during welding that
do not form a part of the weld.
Preventive Action
3. Use Refrasil to protect surrounding surfaces
from secondary weld spatter.
7. Use ceramic tape or approved metal backing
strap on areas with root gap.
8. Consult local Welding Engineering in cases
where the base material is magnetized.
Corrective Action
1. Completely remove spatter from all intermediate weld areas.
2. Remove all loose spatter with a needle gun.
3. Grind all tightly adhering, unacceptable
spatter until it blends smoothly into the base
material or weld.
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SLAG
A 1/8" wide x 1/8" deep notch

is for verifying size of slag
1/4"
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SLAG
Denition
The nonmetallic layer that forms on top of the
molten metal.
Preventive Action
Note: Slag is a byproduct of the welding process
that cannot be prevented. Below are some
actions that make slag removal easier.
2. Maintain a consistent travel speed.
3. Maintain an appropriate arc length/wire stickout.
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minimizing valleys.
Corrective Action
1. Completely remove slag from all intermediate
weld areas.
2. Remove all loose slag with a needle gun.
3. Grind all tightly adhering, unacceptable
slag from the surface of the base material or
weld.
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WELD REINFORCEMENT
* Check local procedures

for areas that have
height restrictions.
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WELD REINFORCEMENT
Denition
The amount of weld that is above a straight line
drawn from the edges of the joint preparation of a
groove weld.
Preventive Action
1.
2.
3.
4.
5.
Adjust amps/volts.
Maintain appropriate wire stickout.
Sequence beads so that the toes do not
excessively overlap one another, creating high
spots in the reinforcement.
Corrective Action
Grind or carbon arc areas of weld reinforcement
that exceed the maximum allowable height (if
applicable).
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MELT THROUGH
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MELT THROUGH
Denition
Excessive heat and/or penetration that results
in irregularity on the surface of the backing ring
or strip, fused root or adjacent base material.
Preventive Action
1. Reduce amps/volts.
2. Increase travel speed.
4. Use ceramic tape or approved metal backing strap on areas with root gap.
Corrective Action
1. Grind or carbon arc the weld to sound
metal.
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OFFSET
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OFFSET
Denition
A situation where base materials creating a butt
or corner joint have moved out of alignment or
position. Sometimes called misalignment.
NOTE: Offset is one of the major causes of inservice failures!
Preventive Action
(QVXUHLQVWDOOLQJWUDGHSURYLGHVSURSHUWXS
prior to welding.
2. Use approved temporary attachments
VWURQJEDFNVDWEDUHWFDVQHHGHGWR
reduce distortion.
3. Gauge for offset acceptability prior to tack
ZHOGLQJZLWKEULGJHFDPRUQJHUJDXJHV
$SSO\VXIFLHQWEORFNWDFNVSULRUWRZHOGLQJ
Note: Stop welding and immediately notify your
foreman anytime unacceptable offset
occurs.
Corrective Action
,QVWDOOLQJWUDGHPD\KDYHWRFXWDSDUWDQGUHW
the joint within tolerance.
2. Offset may be repaired by applying weld buildup to the appropriate taper.
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OXIDATION
coppernickel
steel
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OXIDATION
Denition
A condition resulting from partial or complete
lack of purge of a surface which is heated during
welding resulting in formation of oxide on the
surface. This condition may range from slight
oxidation evidenced by a multicolored or tightly
DGKHULQJEODFNOPWRWKHH[WUHPHRIDYHU\URXJK
surface having crystalline appearance (referred to
as sugaring.)
Preventive Action
1. Ensure adequate pipe purge is maintained
prior to and throughout the welding process.
Corrective Action
1. Grind the weld to sound metal.
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CRATER PIT
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CRATER PIT
Denition
A hole extending into the weld resulting from
shrinkage during cooling.
Preventive Action
2. When breaking the arc for TIG welding, rapidly pop the trigger several times to avoid
VXGGHQSXOORIIV7KLVZLOOSURYLGHVXIFLHQW
post purge of the weld puddle.
Corrective Action
1. Grind the weld to sound metal.
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PAINT
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PAINT
Denition
A pigmented oil or liquid that forms a coloring or
protective coating when dry. May be found on the
weld face or in the weld inspection area.
Preventive Action
Ensure installing trade adequately removes paint,
paint stick markings and metal marker writings in
WKHZHOG]RQHSULRUWRWWLQJDQGZHOGLQJ
Corrective Action
Grind, wire wheel or needle gun the weld zone
free of paint prior to welding.
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Butt
(Square)
(Single V)
(Double V)
(Single U)
Tee
(Square)
(Single Bevel)
(Single J)
(Double Bevel)
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Corner
(Square)
(Single
Bevel)
(Single J)
(Single U)
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Lap
Edge
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Parts of a Weld
* This represents the theoretical throat (the minimum speciHGOHJVL]HPXOWLSOLHGE\ZKLFKLVWKHVKRUWHVWGLVWDQFH

from the joint root to the hypotenuse (straight line drawn toe
to toe) of the largest right triangle that can be drawn within
WKHOOHWZHOGFURVVVHFWLRQ
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B2V.3
Structural Joint
Numbering System
First character (Letter)
Designates type of joint:
B - Butt
C - Corner
T - Tee
L - Lap
PT - Partial Penetration
E - Edge
Second Character (Number)
Designates Number of Sides
Welded:
1 - Welded One Side
2 - Welded Both Sides
Third Character (Letter)
Designates Conguration of
Joint:
S - Square Groove
V - Beveled or V Groove
U - U-Shaped Groove
J - J-Shaped Groove
Period Used for Separation
Fourth Character (Number)
Is Assigned In Sequence, 1,2,3,
Etc., to Cover Distinctive Joint
Differences such as Bevel Angle,
Root Opening, With Backing,
Without Backing, Etc.
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Structural Joint
Numbering System
EXAMPLES
C1V.2
Single Beveled
Groove
Corner Joint
Welded One Side
55
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Structural Joint
Numbering System
EXAMPLES
T2V.2
Tee Joint
Double Beveled
Groove
Welded Both Sides
56
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Structural Joint
Numbering System
EXAMPLES
B2V.1
Butt Joint
Single V
Groove
Welded Both Sides
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Structural Joint
Numbering System
EXAMPLES
B1V.1
Butt Joint
Single V
Groove
Welded One Side
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Structural Joint
Numbering System
EXAMPLES
B2V.3
Butt Joint
Double V Groove
Welded Both Sides
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Standard Welding Symbol

Layout
Weld Size
(Far or Other Side)

(Near or Arrow Side)
Elements in this
area as shown
regardless of
arrow orientation
Reference Arrow
Weld all around
Symbol
Reference Line
Weld Symbol
or Reference
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Fillet Near Side
Fillet Far Side
Fillet Both Sides
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V Groove Near Side
V Groove Far Side
V Groove Both Sides
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Single Bevel Near Side
Single Bevel Far Side
Double Bevel
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Single Beveled Tee Joint
Welded One Side / Fillet Reinforced
T1V.1
Joint has
a bevel
Fillet size
near side
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Single Beveled Tee Joint
Welded Both Sides / Fillet Reinforced
T2V.1
Fillet size
far side
Joint has
a bevel
Fillet size
near side
Note: Backgouge and visual
inspection required
65
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Partial Penetration
Double Bevel Tee Joint
Welded both sides / Fillet Reinforced
Example of PT2V.1
6 OOHWVL]H
B = depth of bevel
S
B
Fillet size
far side
Joint is
beveled
both sides
Fillet size
near side
3/8 Fillet
size far
side
Joint is
beveled
1/2 deep
both sides
3/8
1/2
3/8
3/8 Fillet
size near
side
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Using Finger Gauge to Measure:

Concavity
Check Concavity using

Convexity
Check Convexity using
Overlap/Roll Over
Overlap angle
less than 90
67
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Use Finger Gauge to Measure Skewed

Fillet and Fillet Reinforced Welds
Gauging Skewed Welds
Finger gauges are the only gauges capable of
gauging skewed welds.
Note that when the angle of the joint preparation
is less than 90 the actual length of the weld legs
will increase.
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Finger Gauge to Measure Spatter/Slag
A 1/8" wide x 1/8" deep notch is

for verifying size of spatter/slag
1/4"
Measuring
Slag
Measuring
Spatter
69
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Using Bridgecam Gauge To Measure:

Fillet Weld Throat
Read from theoretical
throat scale.
Fillet Leg Length
70
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Using Bridgecam Gauge To Measure:

Reinforcement
Offset
71
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Table of Contents
Using Gauges to Measure:

Undercut
UNDERCUT GAUGE
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Denitions
1. Completed weld A weld that is completed and is
UHDG\IRUQDOYLVXDOLQVSHFWLRQ
2. Defect Any harmful discontinuity that must be repaired
to be acceptable.
3. Discontinuity Any imperfection in the normal structure
RUFRQJXUDWLRQRIDZHOGRUWKHEDVHPDWHULDOWKDWmay
or may not need to be repaired.
4. Final visual inspection of welds Visual inspection
SHUIRUPHGRQDFRPSOHWHGZHOGLQWKHQDOVXUIDFH
condition and heat-treated condition.
5. Finished weld$ZHOGWKDWKDVUHFHLYHGQDO
inspection and has been accepted.
6. In-process visual inspection of welds- Visual
inspection performed on intermediate passes of multipass welds.
7. Sound metal Metal that contains no defects.
. Skewed llet welds)LOOHWRUOOHWUHLQIRUFHGZHOGWKDWLV
less than 85 or greater than 95.
i
NDT Nondestructive Testing

VT = Visual Inspection
MT = Magnetic Particle Inspection
PT = Liquid Penetrant Inspection
UT = Ultrasonic Inspection
RT = Radiographic Inspection
ET = Eddy Current Inspection
73
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Scale Divisions Reference

English
Metric
-7/32
-3/16
-5/32
- 5mm
-1/8
-3/32
- 6.35
mm
-1/16
-1/32
1/64
3/64
5/64
7/64
9/64
11/64
13/64
-1/4
1/32
1/16
3/32
1/8
5/32
3/16
7/32
1/4
9/32
5mm
5/16
11/32
13/32
3/8
10mm
7/16
15/32
1/2
17/32
9/16
19/32
21/32
15mm
5/8
11/16
23/32
3/4
25/32
13/16
27/32
20mm
7/8
29/32
15/16
31/32
25mm
25.4
mm
Note: For training purposes only. Not to Scale!
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Welders Visual Inspection Handbook 2013 WEB New PDF

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WELDERS

-- NOTE -This handbook is NOT intended to serve as a work

Click on any of the items under the Table of Contents to go to that

Visual Inspection Responsibilities

When Final visual inspections must be performed:

Visual Inspection Technique

How to Measure FILLET WELD SIZE

UNDERSIZED FILLET WELD

* See parts of a weld

UNDERSIZED FILLET WELD

CONCAVE FILLET WELD

CONCAVE FILLET WELD

CONVEX FILLET WELD

Check Convexity using

CONVEX FILLET WELD

OTHER FABRICATION SCARS

OTHER FABRICATION SCARS

A 1/8" wide x 1/8" deep notch

A 1/8" wide x 1/8" deep notch

* Check local procedures

Types of Weld Joints

Types of Weld Joints

Types of Weld Joints

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Welded One Side

Welded Both Sides

Welded Both Sides

Welded One Side

Welded Both Sides

Standard Welding Symbol

(Far or Other Side)

Standard Welding Symbols

Fillet Near Side

Fillet Far Side

Fillet Both Sides

Standard Welding Symbols

V Groove Far Side

V Groove Both Sides

Standard Welding Symbols

Single Bevel Near Side

Single Bevel Far Side

Standard Welding Symbols

Standard Welding Symbols

Standard Welding Symbols

Using Finger Gauge to Measure:

Check Concavity using

Use Finger Gauge to Measure Skewed

Finger Gauge to Measure Spatter/Slag

A 1/8" wide x 1/8" deep notch is

Using Bridgecam Gauge To Measure:

Fillet Leg Length

Using Bridgecam Gauge To Measure:

Using Gauges to Measure:

NDT Nondestructive Testing

Scale Divisions Reference

Note: For training purposes only. Not to Scale!

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